Device and method for sorting items, such as rolls

ABSTRACT

The device for sorting items, such as rolls, is provided downstream of a first number (N) of feeding channels (Ca) of items (R), which feeding channels (Ca) are provided with dispensing members ( 8 ) for a controlled release of the items (R). The device ( 100 ) includes: a number of mobile tracks ( 5 ) equal to the first number (N), arranged downstream of the N feeding channels (Ca) and operatively associated in pairs, so as to define operating gaps (H 1 ) between successive pairs. The first mobile tracks ( 5 ) are movable in reciprocal synchronism, transversally (W) to the feeding channels (Ca). A second number (M) of second mobile tracks ( 6 ) are arranged downstream of the feeding channels (Ca) and are disposed each one between successive pairs of the first tracks ( 5 ) at the operating gaps (H 1 ). The second tracks ( 6 ) are movable both in synchronism with the first tracks ( 5 ), transversally (W) to the feeding channels (Ca), and in phase relation with operation of the first tracks ( 5 ), transversally (W 1 ) to the feeding channels (Ca), within the operating gaps (H 1 ).

TECHNICAL BACKGROUND OF THE INVENTION

The present invention relates to the technical field of automatic linesfor forming and packaging parcels of items, such parcels usuallyconsisting of one or more rows of items arranged in one or more layersand wrapped into protective sheet of heat-weldable type plasticmaterial.

More in particular, the present invention relates to a device and methodfor sorting a series of items in output from a plurality of feedingchannels and directed to a receiving section, so as to arrange the sameitems according to one or more side-by-side transversal rows.

DESCRIPTION OF THE PRIOR ART

As known, in current lines for forming and packaging items, such astoilet paper rolls, blotting paper rolls etc., the latter are firstformed and singled out, at special operating stations, and then routedtowards a complex apparatus known as “diverter” or “combiner” or“sorting machine”, which sorts and conveys such items towards a seriesof feeding channels, in equal, smaller or larger number than the linesfeeding the same apparatus.

Such feeding channels, in co-operation with relevant dispensing members,feed the rolls towards successive stations, so as to define the parcelto be packaged.

Starting from a predetermined number of such feeding channels, usuallyprovided in the maximum number of four, the sequences currently usedallow realising parcels consisting of side-by-side transversal rows,each comprising a smaller number of rolls than the number of the abovefeeding channels, or at most a number of rolls equal to the number ofthe same feeding channels.

It is evident that the above operating procedures used in the currentlines for forming and packaging parcels of rolls set a limit to thepossibility of packaging a parcel with transversal rows comprising anynumber of rolls, for example larger than the number of feeding channelsby one or more units.

This certainly is a disadvantage for the current lines for forming andpackaging parcels of items.

SUMMARY OF THE INVENTION

A main object of the present invention is that of proposing a device anda method for sorting items, in particular rolls, which should remedy theabove disadvantages yet to be overcome and present in the prior art.

More in particular, a fundamental object of the present invention is toprovide a device and a method for sorting items, for example rolls,which starting from any predetermined number of channels for feeding aplurality of single items, should allow sorting them so as to definetransversal rows of items comprising a larger number—by at least oneunit—than the number of said feeding channels, and transferring saidrows towards the successive operating stations to complete thepackaging.

Another object of the invention is to propose a device and a method forsorting items, for example rolls, capable of ensuring high reliabilityand performance standards in any operating step, and such as to meet anyrequirement for forming parcels in any number of items for eachtransversal row of the same.

The above objects are entirely achieved according to what reported inthe claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention will appear more clearly from thefollowing description of preferred but non-exclusive embodiments of thedevice for sorting items, object of the present invention, as well asrelevant exemplifying but non-limiting sequences of operating steps ofthe proposed method, with reference to the attached drawings. In suchdrawings:

FIGS. 1, 2, 3, 4, 5, 6, 7, 8, show schematic plan views of a firstpossible embodiment of the device for sorting items, such as rolls,subject of the present invention, as well as the sequence of theoperating steps of the method relating to an example of formation ofparcels of items consisting of transversal rows comprising a number ofitems which is larger by one unit than the number of feeding channels;

FIGS. 8 a and 8 b show schematic plan views of two possible variants ofsequence of operating steps of the proposed device;

FIGS. 9, 10, 11, 12, 13, 14, 15, 16, 17, show schematic plan views of asecond possible embodiment of the device for sorting items, such asrolls, which is the subject of the present invention, as well as thesequence of the operating steps of the method, relating to an example offormation of parcels of items consisting of transversal rows comprisinga number of items which is larger by one unit than the number of feedingchannels.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The method for sorting items, such as rolls, which is the subject of thepresent invention, basically provides for the following steps: arranginga series of items R within a first number N of feeding channels Ca ofsaid items, said N feeding channels Ca being provided, at the relevantoutput sections, with dispensing members S for a controlled release ofsaid items R according to predetermined sequences; operating mobiletracks 5, 6, 8, provided downstream of said N feeding channels Ca andincluding at least one supplementary track in addition to the number ofsaid N feeding channels Ca, in phase relation with the actuation of saiddispensing members S and in accordance with the above predeterminedsequences, so as to face said N feeding channels Ca and receive theitems released by them, and so as to define, in co-operation with thedriving bars 7, at least one transversal row Z of items comprising atleast one additional item to the number N of said feeding channels Caand afterwards transfer at least said row Z towards successive packagingoperating stations.

With reference to the attached drawings, in particular from FIG. 1 toFIG. 8, reference numeral 100 denotes a first embodiment of the devicefor sorting items, such as rolls, which is the subject of the presentinvention.

Such device 100 is provided downstream of N feeding channels Ca of aseries of items R formed and singled out at previous apparatus (notshown), said N feeding channels Ca being associated in pairs, the latterbeing spaced from one another by equal steps H, and provided, at therelevant output sections, with dispensing members S for a controlledrelease of said items R.

The device 100 is also provided with N first mobile tracks 5, arrangeddownstream of said N feeding channels Ca and operatively associated inpairs, so as to exhibit operating gaps H1 between successive pairs,facing the above steps H.

Such N first mobile tracks 5 can be moved in reciprocal synchronism,transversally W to the N feeding channels Ca.

The device 100 is also provided with a second number M of second mobiletracks 6, each arranged downstream of the N feeding channels Ca andinserted between successive pairs of said N first tracks 5 at theoperating gaps H1.

Such M second tracks 6 can be moved both in synchronism with the N firsttacks 5, transversally W to the N feeding channels Ca, and in phaserelation with the N first tracks 5, transversally W1 to the N feedingchannels Ca in the operating gaps H1.

The N first tracks 5 and the M second tracks 6, following thecorresponding movements, respectively in synchronism for the N firsttracks 5 and in a sequence, in synchronism with the first tracks and inphase relation with the first tracks, for the M second tracks 6, areintended to face the N feeding channels Ca according to predeterminedsequences, for receiving items in a number equal to the sum of the firstnumber N and of the second number M (N+M). The items are released byfeeding channels for defining, in co-operation with driving bars 7moving longitudinally above the same first 5 and second 6 tracks forcontacting and pulling such items, respective and distinct transversalrows Z of M+N items and for transferring the same rows Z of M+N itemstowards successive packaging operating stations.

The above N first tracks 5 and the M second tracks 6 are interlockedwith two separate and independent actuating members, not shown.

Optionally, it is possible to provide for the interlocking of both the Nfirst tracks 5 and the M second tracks 6 with the same actuating member.

In particular in figures from 1 to 8, device 100 is shown considering,merely by way of an example, a number N of feeding channels Ca equal tofour (N=4), respectively indicated with reference numerals C1, C2, C3,C4.

Channels C1 and C2, as well as channels C3, C4, are reciprocallycoupled: the distance between the pairs is equal to step H.

Accordingly, device 100 is provided with four first mobile tracks 5,respectively indicated with reference letters A, B, D, E, and coupledtwo by two, that is, A with B, and D with E. The two pairs of tracks A,B and D, E are spaced from one another by an operating gap H1 withinwhich there is provided a single second mobile track 6, indicated withreference letter C.

The operation of device 100 is described hereinafter, considering asinitial configuration that shown in FIG. 1, and illustrating anexemplifying possible mode for actuating the same device for formingfour successive transversal rows Z, each consisting of five items.

Formation of the First Row (Reference Shall be Made to FIGS. 1 and 2)

The dispensing members S release four items R, each from a correspondingfeeding channel C1, C2, C3, C4 of the four feeding channels Ca.

Such four items are received by tracks B, D, E of the first mobiletracks 5, and by track C.

In phase relation with the release of the above four items, the first 5and the second 6 mobile tracks are actuated in reciprocal synchronism,transversally W to the feeding channels Ca, so as to get theconfiguration of FIG. 2, that is: track A faces channel C1, track Bfaces channel C2, track C is arranged at step H, and is thereforeinoperative, track D faces channel C4.

Then, the dispensing member S of channel C1 releases a correspondingitem, which inserts in track A and, at the same time, the driving bar 7,longitudinally mobile above the first and second mobile tracks, contactssuch items to define the first row of five items and transfer the samedownstream, towards successive operating stations.

Formation of the Second Row (Reference Shall be Made to FIGS. 3 and 4)

Track C is actuated in phase relation with the operation of the drivingbar 7, transversally W1 to the feeding channels Ca within the operatinggap H1 so as to face channel C3.

At this point, the dispensing members S release four items R, each froma corresponding feeding channel C1, C2, C3, C4 of the four feedingchannels Ca.

Such four items are received by tracks A, B, D of the first mobiletracks 5, and by track C.

In phase relation with the release of the above four items, the first 5and the second 6 mobile tracks are actuated, in reciprocal synchronism,transversally W to the feeding channels Ca, so as to reach theconfiguration of FIG. 4, that is: track B faces channel C1, track Dfaces channel C3, track C is arranged at step H, and is thereforeinoperative, track E faces channel C4.

Now, the dispensing member S of channel C4 releases a correspondingitem, which enters track E and at the same time, the driving bar 7,longitudinally mobile above the first and the second mobile tracks, goesin contact with such items to define the second row of five items andtransfer the row downstream, towards successive operating stations.

Formation of the Third Row (Reference Shall be Made to FIGS. 5 and 6)

The dispensing members S of channels C3 and C4 release two items R, eachfrom a corresponding feeding channel C3, C4 of the four feeding channelsCa.

Such two items R are received by tracks D, E of the first mobile tracks5.

In phase relation with the release of the above two items, the first 5and the second 6 mobile tracks are actuated, in reciprocal synchronism,transversally W to the feeding channels Ca, so as to reach theconfiguration of FIG. 6, that is: track A faces channel C1, track Bfaces channel C2, track C faces channel C3, whereas track D faceschannel C4.

After this configuration has been set, the dispensing member S ofchannels C1, C2 and C3 release three items, each from a correspondingfeeding channel C1, C2, C3 of the four feeding channels.

Such three items are respectively received by tracks A, B and C.

In phase relation with the release of the last three items, the drivingbar 7 goes to contact the items to define the third row of five itemsand transfer the row downstream, towards successive operating stations.

Formation of the Fourth Row (Reference Shall be Made to FIGS. 7 and 8)

Track C is actuated in phase relation with the operation of the drivingbar 7, transversally W1 to the feeding channels Ca within the operatinggap H1 so as to arrange at step H and adjacent to track B.

The dispensing members S of channels C1 and C2 release two items R, eachfrom a corresponding feeding channel C1, C2 of the four feeding channelsCa.

Such two items R are received by tracks A, B of the first mobile tracks5.

In phase relation with the release of the above two items, the first 5and the second 6 mobile tracks are actuated, in reciprocal synchronism,transversally W to the feeding channels Ca, so as to reach theconfiguration of FIG. 8, that is: track B faces channel C1, track Cfaces channel C2, track D faces channel C3, whereas track E faceschannel C4.

Then, the dispensing member S of channels C2, C3 e C4 release threeitems, each from a corresponding feeding channel C2, C3, C4 of the fourfeeding channels.

Such three items are respectively received by tracks C, D and E.

In phase relation with the release of the last three items, the drivingbar 7 goes to contact the items to define the fourth row of five itemsand transfer them downstream, towards subsequent operating stations.

It should be noted that the configuration of the first 5 and of thesecond 6 mobile tracks reached in such operating step (FIG. 8),coincides with that of FIG. 1, that means that the, device 100 is readyto carry out further sequences to define further transversal rows offive items.

In addition, the above device 100 is capable of realising multipletransversal rows of five items; in fact, it is sufficient to have thedispensing members carry out multiple releases of items upon eachactivation: reference should be made, for example, to FIG. 8 a, whichshows the multiple release of two items.

In the example described, device 100 has sorted items starting from fourchannels to obtain rows of five items; in any case, the same device cansort items starting from two feeding channels, such as C1 and C4, toobtain rows of four items (reference should be made, for example, toFIG. 8 b).

With reference to the attached drawings, in particular from FIG. 9 toFIG. 17, a further possible embodiment of the device is shown (indicatedwith reference numeral 200) for sorting items R, such as rolls, which isthe subject of the present invention.

Device 200 is provided with a third number T of mobile tracks 8 arrangeddownstream of the N feeding channels Ca and comprising an additionaltrack Ts to the number of the latter.

Such T mobile tracks 8 can be operated one by one and in a sequence, inphase relation with the release of items R by the dispensing members Saccording to predetermined sequences, so as to face the N feedingchannels Ca for receiving T items released by them and defining, inco-operation with driving bars 7 longitudinally mobile above the samemobile tracks 8, respective and distinct transversal rows Z of T items,to transfer the same rows Z of T items towards subsequent packagingoperating stations.

Such T mobile tracks 8 may all be interlocked with a same actuatingmember, or as an alternative, each mobile track 8 may be provided with arelevant and corresponding actuating member.

In the attached exemplifying drawings from FIG. 9 to FIG. 17, the firstnumber N of feeding channels Ca has been considered as equal to four,whereas the third number T of the mobile tracks 8 has been considered asequal to five.

The same figures from 9 to 17 schematically show, according to apossible exemplifying operating mode of such embodiment of device 200,the successive operating steps that, starting from four feeding channelsCa, allow obtaining transversal rows Z of items, each comprising fiveitems R.

References C1, C2, C3, C4 denote the N=4 feeding channels, whereas T1,T2, T3, T4, Ts denote the T=5 mobile tracks 8, where Ts is theadditional mobile track to the number of feeding channels.

Formation of the First Row (Reference Shall be Made to FIGS. 9 and 10)

-   -   the dispensing means S are operated to release four items (which        have been indicated with the reference numeral 1), each one from        a relevant channel C1, C2, C3, C4 of the four feeding channels        Ca, and the above-mentioned four items are directed into the        relevant first four mobile tracks T1, T2, T3, T4 of the five        mobile tracks 8;    -   the dispensing means S are operated again for releasing an        additional item (also indicated with the reference numeral 1)        from the first channel C1 of the four feeding channels, and at        the same time the mobile tracks 8 are operated so as to direct        this additional item to the mobile track, of the above-mentioned        mobile tracks, which is not engaged by any of the items released        previously; in particular, the additional item is directed to        the supplementary track Ts of the mobile tracks 8;    -   the driving bar 7 is operated for contacting such items to        define the first row of five items and to transfer the row        towards subsequent operating stations.

Formation of the Second Row (Reference Shall be Made to FIGS. 11 and 12)

-   -   the dispensing means S are operated to release four items (which        have been indicated with the reference numeral 2), each one from        a relevant channel C1, C2, C3, C4 of the four feeding channels        Ca, and the above-mentioned four items are directed into        relevant four mobile tracks of the five mobile tracks 8; in        particular, the item released by the first feeding channel C1 is        directed to the supplementary mobile track Ts whereas the other        items released by relevant channels (that is to say the second        C2, third C3, fourth C4 channels) are directed to the relevant        mobile tracks which face them (which are the second T2, the        third T3 and the fourth T4 tracks);    -   the dispensing means S are operated again for releasing an        additional item (also indicated with the reference numeral 2)        from the second channel C2 of the four feeding channels, and at        the same time the mobile tracks 8 are operated so as to direct        this additional item to that mobile track, of the        above-mentioned five mobile tracks, which is not engaged by any        of the four items released previously; in particular, the        additional item is directed to first mobile track T1;    -   the driving bar 7 is operated for contacting such items to        define the second row of five items and to transfer the row        towards subsequent operating stations.

Formation of the Third Row (Reference Shall be Made to FIGS. 13 and 14)

-   -   the dispensing means S are operated to release four items (which        have been indicated with the reference numeral 3), each one from        a relevant channel C1, C2, C3, C4 of the four feeding channels        Ca, and the above-mentioned four items are directed to relevant        four mobile tracks of the five mobile tracks 8; in particular,        the item released by the first feeding channel C1 is directed to        the supplementary mobile track Ts and the item released by the        second channel C2 is directed to the first mobile track T1,        whereas the other items released by relevant channels C3 and C4        are directed to the relevant mobile tracks, i.e. the third T3        and the fourth T4 tracks;    -   the dispensing means S are operated again for releasing an        additional item (also indicated with the reference numeral 3)        from the third channel C3 of the four feeding channels, and at        the same time the mobile tracks 8 are operated so as to direct        this additional item to that mobile track, of the        above-mentioned five mobile tracks, which is not engaged by any        of the four items released previously; in particular, the        additional item is directed to second mobile track T2;    -   the driving bar 7 is operated for contacting such items to        define the second row of five items and to transfer the row        towards subsequent operating stations.

Formation of the Fourth Row (Reference Shall be Made to FIGS. 15, 16 and17)

-   -   the dispensing means S are operated to release four items (which        have been indicated with the reference numeral 4), each one from        a relevant channel C1, C2, C3, C4 of the four feeding channels        Ca, and the above-mentioned four items are directed to relevant        four mobile tracks of the five mobile tracks 8; in particular,        the item released by the first feeding channel C1 is directed to        the supplementary mobile track Ts, the item coming from the        second feeding channel C2 is directed to the first mobile track        T1, the item coming from the third feeding channel is directed        to the second mobile track T2, whereas the item released by the        fourth feeding channel C4 is directed to the corresponding        fourth mobile track T4;    -   the dispensing means S are operated again for releasing an        additional item (also indicated with the reference numeral 4)        from the fourth channel C4 of the four feeding channels, and at        the same time the mobile tracks 8 are operated so as to direct        this additional item to that mobile track, of the        above-mentioned five mobile tracks, which is not engaged by any        of the four items released previously; in particular, the        additional item is directed to third mobile track T3;    -   the driving bar 7 is operated for contacting such items to        define the fourth row of five items and to transfer the row        towards subsequent operating stations.

It is evident from what has been described above that the proposeddevice, in both the embodiment herein illustrated, makes it possible toobtain, in advantageous way, by means of a succession of extremelysimple subsequent steps, and with extremely reliable modes, parcels ofitems arranged in transversal rows, each row including a number of itemlarger than the number of single items feeding channels, for examplelarger by one unit.

It should be noted that the item sorting device subject of the presentinvention makes it possible to eliminate the complex sortingapparatuses, which have been used up to now in the current packaginglines and commonly known as “diverter” or “combiner” or “sortingmachine”.

Undoubtedly, this is a remarkable advantage in consideration of bothdesign time and reduction of costs, and also in consideration of theremarkable simplification of the operative modes and operation of theitem parcels packaging lines.

Furthermore, the method for sorting the items as described above allowsovercoming the drawbacks currently present in the prior art apparatuses,thus giving the forming and packaging automatic lines a great deal ofoperational flexibility.

In fact, the proposed method allows forming and packaging parcels ofitems composed by transversal rows comprising any desired number ofitems, which number is independent from the pre-fixed and pre-determinednumber of feeding channels; in particular, the proposed method allowsitem parcels to be obtained, which parcels are composed of transversalrows each one including a number of items larger than the number offeeding channels by at least one unit.

It should also be noted that, the proposed method, after a number ofcycles formed by repetition of the relevant operating steps equal to thenumber N of feeding channels, makes it possible to take over the samenumber of items from each one of the feeding channels.

All what is described above is intended as an unlimited example only, sothat possible variants in the succession or in carrying out the variousoperation steps, for instance the dispensing means or the movable buffermeans operation modes, are anyway considered within the protective scopeaccorded to the present technical solution, as described above andclaimed in the following.

1. A device for sorting items, provided downstream of a first number offeeding channels of a series of items formed and singled out at previousoperative stations, said feeding channels being associated in pairs, thelatter being spaced from one another by equal steps, and provided, atthe relevant output sections, with dispensing members for a controlledrelease of said items, wherein said device includes: a number of mobiletracks equal to said first number of feeding channels, said mobiletracks being arranged downstream of said feeding channels andoperatively associated in pairs, so as to define operating gaps betweensuccessive pairs, the gaps facing the above steps, said first mobiletracks being movable in reciprocal synchronism, transversally to saidfeeding channels; a second number of second mobile tracks, each arrangeddownstream of said feeding channels and disposed between successivepairs of said first tracks at the operating gaps, said second tracksbeing movable both in synchronism with said first tracks, transversallyto said feeding channels, and in phase relation with operation of saidfirst tracks, transversally to said feeding channels within saidoperating gaps; said first tracks and said second tracks being designed,due to corresponding movements respectively in synchronism, the firsttracks, and in a sequence, in synchronism with the first tracks and inphase relation with the first tracks, the second tracks, to face saidfeeding channels according to predetermined sequences, for receivingitems in a number equal to the sum of said first number of mobile tracksand of said second number of second mobile tracks, said items beingreleased by said feeding channels for defining, in cooperation withdriving bars moving longitudinally above the same first and secondtracks, for contacting and pulling such items, respective and distincttransversal rows of items, each transversal row including a number ofitems equal to the sum of said first number and second number of mobiletracks, and for transferring the same rows of items towards subsequentpackaging operating stations.
 2. A device according to claim 1, whereinsaid items, which are in a number equal to the sum of said first numberand second, number, are released by said feeding channel by means ofrelated dispensing means, in accordance with predetermined sequenceswhich correspond to the operational sequence of said first tracks andsaid second tracks.
 3. A device according to claim 1, wherein said firstmobile tracks are interlocked with a first actuating member and saidsecond mobile tracks are interlocked with a second actuating member,said first actuating member and said second actuating member beingindependent from one another.
 4. A device according to claim 1, whereinsaid first mobile tracks and said second mobile tracks are interlockedwith a common actuating member.
 5. A device according to claim 1,wherein said feeding channels release single items in accordance withpredetermined sequences, which correspond to the operation of said firsttracks and said second tracks, so as to obtain single transversal rows,each row including a number of items equal to the sum of said firstnumber and second number.
 6. A device according to claim 1, wherein saidfeeding channels carry out multiple release of items in accordance withpredetermined sequences, which correspond to the operation of said firsttracks and said second tracks, so as to obtain multiple transversalrows, each row including a number of items equal to the sum of saidfirst number and second number.
 7. A method for sorting items, whereinthe method includes: arranging a series of items within a first numberof feeding channels of said items, said feeding channels being provided,at the relevant output sections, with dispensing members for acontrolled release of said items according to predetermined sequences;operating a first number of first mobile tracks equal to said firstnumber of feeding channels, said mobile tracks operated in reciprocalsynchronism, and a second number of second mobile tracks, operativelyassociated to said first mobile tracks, which can be operated both insynchronism with said first tracks, and in phase relation with theoperation of these latter, said first tracks and second tracks defininga third number of mobile tracks provided downstream of said feedingchannels and being designed to be operated in a way that they face saidfeeding channels for receiving items released by said dispensing membersin a number equal to the sum of said first number and said second numberof mobile tracks, in accordance with said predetermined sequences, andfor defining, in co-operation with driving bars moving longitudinallyabove the same mobile tracks for contacting and pulling such items,respective and distinct transversal rows of items, each transversal rowincluding a number of items equal to the sum of said first number andsecond number of mobile tracks, and for transferring the same rowstowards subsequent packaging operating stations.